Development of an online-capable warning system for process instabilities on the basis of stability limits calculated in a process-parallel approach
Final Report Abstract
The project aimed to develop an online-capable Chatter-Alert System to detect instabilities during machining and enable data-driven process optimizations. Key outcomes included the successful identification of machine dynamics, the process-parallel determination of cutting stiffness, and the targeted simulation of stability limits, which collectively form the basis for precise and efficient stability analysis. Through experimental-analytical substructure coupling, the measurement effort required to determine machine dynamics was significantly reduced. Simultaneously, a process-parallel identification of cutting stiffness using an Ensemble Kalman Filter allowed for reliable adaptation to real process conditions. The stability limit simulation focused specifically on relevant operating points, enabling the successful implementation of a model-based stability simulation for process-parallel application. Milling tests confirmed the system's ability to accurately predict instabilities and optimize process parameters. The Chatter-Alert System integrates the collected data and findings into a user-friendly prototype software tool. It synchronizes real-time data, monitors the machining process, and visualizes stability states. A manual chatter detection function complements the automated analysis, addressing unforeseen instabilities as well. Integration into a central database allows for scalable data storage and longterm process optimization. Validation on complex components demonstrated that the system can not only detect instabilities early but also eliminate them through targeted adjustments of machining parameters. This led to a significant increase in productivity and machining quality while reducing waste and tool wear. The project illustrates how modern analysis methods, data-driven models, and innovative software solutions can be combined to make manufacturing more economical, stable, and resource-efficient. The Chatter-Alert System provides a practical and effective solution for optimizing modern machining processes.
Publications
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Onlinefähiges Ratter-Frühwarnsystem. Modellbasierte Identifikation von Prozessinstabilitäten mit prozessparalleler Datengrundlage. In: VDI-Z, 165. Jg., 2023, 07-08, S. 15–17
Brecher, C.; Fey, M. & Wittmann, M.
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Online-Frühwarnsystem: Ratterfrei Fräsen/Online Alert System: Chatter-free milling. wt Werkstattstechnik online, 114(05), 205-212.
Brecher, Christian; Fey, Marcel & Wittmann, Marcel
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Methodik zur prozessparallelen Stabilitätsuntersuchung von Werkzeugmaschinen beim Fräsen: Ein modellbasierter Ansatz, Dissertation, RWTH Aachen
Wittmann, M.
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Online-Frühwarnsystem zur Rattervermeidung an Fräsmaschinen. In: NCFertigung, Heft 1-2025
Brecher, C.; Fey, M. & Wittmann, M.
